Footwear and apparatus and method for making same

ABSTRACT

A shoe insole ( 28 ) comprises a base layer ( 34 ) and an optional top layer ( 36 ). The base layer ( 34 ) comprises functional zones ( 40 ) configured according to a user&#39;s physiological data, needs, and intended use. The insoles ( 28 ) may either partially or wholly be made using additive manufacturing techniques.

This application claims priority to and incorporates herein by reference in their entirety U.S. provisional application 62/893,579, filed Aug. 29, 2019, and U.S. provisional application 62/836,210, filed Apr. 19, 2019, both entitled “Footwear and Apparatus and Method for Making Same”.

TECHNICAL FIELD

The technology relates to the field of footwear, including but not limited to insole designs and compositions and footwear incorporating the insole designs, as well as method and apparatus for making the insole designs and the footwear incorporating same.

BACKGROUND

Traditional footwear insoles are not fully customized for a user. Rather, insoles are designed to group feet into categories that generally fit a wide variety of feet.

Three dimensional (“3D”) printing technology has been used to limited extent to manufacture portions of footwear. Current 3D printed insoles use 3D printed structure for rigidity, stability, and fit. But current 3D printing technology does not sufficiently address wearer or user comfort. Thus, footwear made with current 3D printing technology typically requires another layer of material to be added, e.g. foam, as a cushion.

Foam is one of many types of materials deployed to enhance insole comfort, and is perhaps one of the most versatile and widely used ways to increase comfort. However, despite the broad adoption of foam, conventional approaches to foam design and experimentation still share a same significant limitation. A limitation of foam utilization for footwear is that compression force applied to foam increases linearly, resulting in, e.g., severe design and comfort constraints.

To address the limitations of foam utilization in footwear, closed-cell foams have been developed to enable an increasingly non-linear load-compression response. However, even the use of closed-cell foams has problems, since any increase in compression performance using closed-cell foams comes at a sizeable cost. For example, the closed-cell foams lack breathability. Lacking breathability, the closed-cell foams demonstrate the thermal profile of an insulator which results in foot discomfort due to heat, e.g., caused by lack of air-flow.

In addition, currently existing monolithic footwear does not have zones of differing character. Accordingly, some footwear requires fabrication and then assembly of multiple parts of layers in order to attempt varying zones of character or performance in the footwear. As a result, insoles are often thick, and less compliant with the shoe's intended comfort.

What is needed are methods, apparatus, and/or techniques for making comfortable footwear incorporating insoles, and the footwear and insoles made thereby.

SUMMARY

The technology described herein relates to a shoe insole comprising a base layer and an optional top layer. The base layer comprises functional zones configured according to a user's physiological data, needs, and intended use. The insoles may either partially or wholly be made using additive manufacturing techniques.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other objects, features, and advantages of the technology disclosed herein will be apparent from the following more particular description of preferred embodiments as illustrated in the accompanying drawings in which reference characters refer to the same parts throughout the various views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the technology disclosed herein.

FIG. 1 is side, top perspective view of footwear according to an example embodiment.

FIG. 2 is a side top perspective view of an insole of a type utilizable in the footwear of FIG. 1.

FIG. 3A is a top, side, rear perspective view of an insole base layer.

FIG. 3B is a top, side, rear perspective view of an insole top layer.

FIG. 4A is a top plan view of an example insole.

FIG. 4B is a bottom plan view of the example insole of FIG. 4A.

FIG. 5 is a diagrammatic view of an example stochastic structure that may form at least one zone of an insole base layer according to an example embodiment and mode.

FIG. 6 is a diagrammatic view of an example auxetic lattice structure that may form at least one zone of an insole base layer according to an example embodiment and mode.

FIG. 7 is a flowchart that shows example, representative acts or steps which may be included in a method of fabricating or making an example embodiment of footwear of the technology disclosed herein.

FIG. 8 is a schematic view of an example embodiment and mode of apparatus which may be employed for fabricating or making footwear according to example modes of the technology disclosed herein, and also shows acts performed by processor circuitry of such apparatus when executing instructions of a computer program product stored on non-transitory tangible media such as in a memory.

FIG. 9 is a diagrammatic view of an example gyroid structure that may form at least one zone of an insole base layer according to an example embodiment and mode.

FIG. 10 is a diagrammatic view of an example Schwartz structure that may form at least one zone of an insole base layer according to an example embodiment and mode.

DETAILED DESCRIPTION

In the following description, for purposes of explanation and not limitation, specific details are set forth such as particular architectures, interfaces, techniques, etc. in order to provide a thorough understanding of the technology disclosed herein. However, it will be apparent to those skilled in the art that the technology disclosed herein may be practiced in other embodiments that depart from these specific details. That is, those skilled in the art will be able to devise various arrangements which, although not explicitly described or shown herein, embody the principles of the technology disclosed herein and are included within its spirit and scope. In some instances, detailed descriptions of well-known devices, circuits, and methods are omitted so as not to obscure the description of the technology disclosed herein with unnecessary detail. All statements herein reciting principles, aspects, and embodiments of the technology disclosed herein, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future, i.e., any elements developed that perform the same function, regardless of structure.

Thus, for example, it will be appreciated by those skilled in the art that block diagrams herein can represent conceptual views of illustrative circuitry or other functional units embodying the principles of the technology. Similarly, it will be appreciated that any flow charts, state transition diagrams, pseudo code, and the like represent various processes which may be substantially represented in computer readable medium and so executed by a computer or processor, whether or not such computer or processor is explicitly shown.

FIG. 1 shows a representative example illustration of an item of footwear 20, e.g., a shoe. In the non-limiting example embodiment of FIG. 1, footwear 20 comprises upper 22; midsole 24; exterior sole or outsole 26; and insole 28. The exterior sole or outsole 26 is configured to interface with a contact surface 30, such as a floor or ground. The upper 22 is attached to the exterior sole 26 and configured to at least partially define a cavity 32 for foot insertion. The insole 28 is insertable into or formed within the cavity 32. Each of these portions can be designed specifically for a user and needs of the user/wearer. As described herein, “footwear” may comprise any combination of upper 22, midsole 24, outsole 26, and insole 28, and therefore need not comprise all portions.

The upper 22 may be the portion of the footwear (such as a shoe) that surrounds the sides and top of a user's foot. The upper 22 may comprise portions, such as a heel support, ankle support, webbing, laces, straps, tongue, and other structures as are known in the art. In some cases the upper 22 may comprise two or more portions that are selectively bound by a user using, for example, laces or straps.

Insole 28 may be the inner portion of footwear (such as a shoe) that directly contacts the bottom (and to some extent side) of a user's foot. Insole 28 may be a fixed, e.g., permanent, portion of a shoe, or a removable portion of a shoe in different instances. Insole 28 may be designed to improve performance, health, prevent injuries, and relieve foot pressure, among other things.

Midsole 24 may be a footwear portion between the insole and the outsole 26, which, in some instances, is a shock-absorbing portion. In some instances, the midsole 24 may be designed to be responsible for supporting a substantial portion of the weight of a user as well as providing shock absorbing properties for the footwear while in use. In other instances, the midsole 24 may be designed to enhance the effectiveness of features found in the insole 28 and/or outsole 26.

Outsole 26 may be the outermost portion of footwear, and may be designed to interface with the ground 30. In some instances, the outsole 26 is alternatively known as a tread. The outsole 26 may be designed with, for example, structures and/or textures for providing grip to the footwear on a variety of surfaces. The outsole 26 may also refer to the bottom plate and studs on cleated shoes. Additionally, the outsole 26 may be designed to protect a user's foot from puncture or other harmful intrusion. As with above, the outsole 26 may additionally be designed to enhance the effectiveness of features found in the midsole 24.

FIG. 2 shows in perspective an example insole 28 as taken out or before insertion in footwear 20. Insole 28 may comprise one or more layers. In some example embodiments and modes insole 28 comprises only one layer, e.g., insole base layer 34 shown in FIG. 3A. In other example embodiments and modes, insole 28 may also comprise insole top layer 36 shown in FIG. 3B. In some example embodiments and modes in which insole 28 comprises two layers, the insole top layer 36 may comprise a suitable material, such as foam, rubber, or fabric, which is laid over or affixed to a top of insole base layer 34. The insole top layer 36 may be affixed using any suitable technique, such as adhesive, glue, or hook-and-loop fasteners.

The insole base layer 34 may also be referred to herein as “base layer”; and insole top layer 36 may also be referred to herein as “top layer”. Unless otherwise specified or evident from the context that a top layer of a multi-layer insole 28 is being described, reference herein to “layer” or “layer of insole” or “layer of insole material” is intended to refer to insole base layer 34. Indeed, as indicated above, some embodiments, the insole 28 and its composition may only be one layer, e.g., base layer 34, in which case the insole base layer 34 is synonymous with insole 28.

FIG. 4A shows a top plan view of an example insole 28, while FIG. 4B shows a bottom plan view of the example insole 28. FIG. 4B particularly shows that insole 28 comprises at least one layer of insole material which is configured to comprise plural zones 40, also referred to herein as functional zones or structural zones. For example, FIG. 4B shows insole 28 as comprising, by way of non-limiting example, toe zone 40T, arch zone 40A, central heel zone 40CH, and peripheral heel zone 40PH. The insole base layer 34 may thus comprise one or more functional zones 40 all connected within the same insole base layer 34, which layer may be a same monolithic part. Although four zones 40 are shown in FIG. 4B, it should be understood that a difference number of plural zones 40 may comprise insole 28. Moreover, in other example embodiments and modes encompassed hereby, the zones 40 may be differently located and described, such as a central toe zone, a peripheral toe zone, a central arch zone, a peripheral arch zone, a pronation heel zone, a supination heel zone, by way of non-limiting and non-exhaustive examples. As described herein, each zone 40 may be specially and even uniquely configured in terms of zone structure and zone material. Each zone may comprise a material structure which is configured individually for the functional zone.

In an example embodiment and mode, insole base layer 34 is made using additive manufacturing techniques and lattice structures that comprise the multiple zones 40 within a same monolithic part. The functional zones 40 can be tailored to the user's physiological data and intended use. In some embodiments, a functional zone 40 represents a unique compression response within the insole. As mentioned above, insole 28 may have any number of functional zones 40. In some example embodiments, a functional zone may be represented or may be characterized by density, member thickness, or overall thickness of its structure, e.g., lattice structure, in the y direction as shown in FIG. 2 within insole base layer 34. For example, if the heel area requires a certain compression response, and the heel area has a different compression response than the areas adjacent to it, then the heel area is a functional zone. For example, if there is much pressure in the heel area, a certain functional zone can be used and configured to compress a certain amount. Additionally, if there is less pressure in the arch area of the foot and there is a desired compression response, a different functional zone may be configured.

In terms of material(s), insole base layer 34 with its zones 40 may be manufactured using additive manufacturing techniques, e.g., 3D printing, and made out of a suitable material such as those described herein as being used for additive manufacturing. For example, the insole base layer 34 may be made of a suitable elastomeric, rubber, or plastic material. In some example embodiments, insole base layer 34 may comprise multiple different materials (e.g. elastomeric, rubber, plastic, etc.) strategically placed to improve performance, comfort, and fit among other things. For example, different zones 40 may be formed of different materials. In some embodiments, insole base layer 34 may be manufactured as a single, monolithic part, even in embodiments where insole base layer 34 comprises multiple functional zones 40 within the same part.

In terms of structure, the zones 40 may include any suitable structure(s), for example, beams, lattices, regular 3D grids, regular or irregular open or closed cell structures, foam or sponge-like formations, trusses, springs, shocks, triclinic structures, monoclinic structures, orthorhombic structures, hexagonal structures, triagonal structures, tetragonal structures, cubic structures, stochastic structures 44 for which an example is shown in FIG. 5, or auxetic lattice structures 46 as shown in FIG. 6, or gyroidal structures 98 as shown in FIG. 9, or Schwartz structures 100 as shown in FIG. 10. Thus, another way to describe a functional zone 40 is with reference to a specific lattice geometry, for example, and without limitation, hex, pillar, or snowflake, that is used to provide a certain compression response. In some example embodiments, insole base layer 34 may comprise multiple functional zones 40 that each may vary in lattice density, lattice type, and may possess a density gradient across one or multiple functional zones 40.

One or more zones 40 may comprise a “unit cell”, which may be replicated through the zone 40. A unit cell may be part of a lattice structure that may be repeated and connected to form a flexible design for insole base layer 34. For example, in some example embodiments and modes, the unit cells of the insole base layer 34 may be designed to be manufactured using the additive manufacturing techniques collectively as one continuous part. In different embodiments, a unit cell may be made in a variety of different shapes and sizes. For example, a unit cell may have a geometric shape, for example, and without limitation, a triangle, square, pentagon, dark horse, snowflake, or icosahedron of a given size. In some example embodiments, the unit cell may be designed to connect to other unit cells, such that a single unit cell may connect to one or more other unit cells. In some example embodiments, the unit cells that make up the base layer can either stay the same or change to help create different functional zones 40 within the same monolithic part. Any type of unit cell may be used at any point within insole base layer 34. For example, a certain pressure profile may require a pentagon unit cell in the heel area and a snowflake unit cell in the arch area to properly support the foot and provide the desired compression response.

The unit cells of the zones 40 can be described as having a lattice construct, including both Triply Periodic Minimal Surface (TPMS) and mass and connector structures. Unit cells of zones 40 may have structures including, but are not limited to, mass and connector structures, regular 3D grids, trusses, triclinic structures, monoclinic structures, orthorhombic structures, hexagonal structures, triagonal structures, tetragonal structures, cubic structures, regular or irregular open or closed cell structures, foam or sponge-like formations, springs, shocks, stochastic structures, and auxetic lattice structures. The unit cells of zones 40 may have Triply Periodic Minimal Surface (TPMS) structures, such as, but not limited to, gyroidal structures and Schwartz structures. The unit cells of zones 40 can also be grouped into categories such as (i) strut-based cellular structures (e.g., Kelvin, Octet-truss, and Gibson-Ashby), (ii) skeletal-TPMS based cellular structures (e.g., Skeletal-MP, Skeletal-Diamond, Skeletal-Gryoid), and (iii) sheet-TPMS based cellular structures (e.g., Sheet-MP, Sheet-Diamon, Sheet-Gyroid, and Sheet-Primitive). The foregoing structures are listed by way of example, and not limitation. Any lattice or even non-lattice construct may be used in the structure of unit cells of the zones 40.

From the foregoing it can be seen that the footwear 20 with its insole 28, particularly with insole base layer 34, has many advantages and features. In some example embodiments and modes, for example, the zones 40 may improve any or all of the following: fit, comfort, performance, and may reduce risk of injury for the user, among other things. Furthermore, a functional zone for a lattice structure, such as stochastic structure 44 shown in FIG. 5, may be based on certain compression response ideals for locations within the insole. Additionally, functional zones 40 may influence characteristics of an insole, such as: elasticity, rigidity, compressive energy capacity, and density, among other things. In addition to the form of the functional zone, the position and size of the functional zone may influence the performance of an insole. Further, the lattice structure in insole base layer 34 does not have to be homogeneous in nature. For example, the stiffness at certain points in the lattice structure may vary based off of the user's physiological data and a desired or recommended compression response. The insole base layer 34 may also be constructed by generating a stochastic lattice structure 44 that may vary in density, beam width, and directionality. In some example embodiments, the lattice geometry in insole base layer 34 may be designed to compress a certain amount under certain loads such that the insole does not bottom out, thus conserving energy that is usually lost. In some example embodiments, the lattice geometry in insole base layer 34 may be designed to increase ground force when compressed. In some example embodiments, the lattice structure in insole base layer 34 may be designed to capture compressive and bending forces to conserve energy and increase the user's performance.

In some example embodiments, the lattice structure in insole base layer 34 of the insole 28 has a much higher compressive life cycle when compared to standard foam insoles, thereby allowing for the structural integrity of the insole to last at least the life of the shoe. This allows for insole foot support to deteriorate at a much slower rate.

In some example embodiments, the lattice can provide tune-ability and control throughout the load-compression curve, making it possible to precisely define the transition points between linear elasticity, the plateau, and densification. Alternatively, insole base layer 34 can be designed with portions of auxetic lattice structures 46 as to exhibit a negative Poisson's ratio over specific areas.

A three dimensionally printed insole 28 comprising a lattice structure may outperform a traditional shoe insole by delivering a superior performance on compression response control, among other ways. Each unit cell in the lattice structure of the insole may be configured to compress a certain amount based on the user's physiological data, in order to preserve the energy that would normally be lost, among other benefits.

In an example embodiment, the lattice structure in insole base layer 34 may be designed with data collected through a 3D scan of the user's feet allowing for the topology of insole base layer 34 to conform to the user's feet, as well as pressure mapping the user's feet so a desired compression response can be designed into each functional zone 40 of insole base layer 34.

In an example embodiment, insole top layer 36 may be flexible enough to map the topology of the base layer in order to not interfere with the designed fit of the insole.

In an example embodiment, the insole can be designed to fit any shoe or shoe size.

In an example embodiment, insole base layer 34 can be designed for multiple uses such as, but not limited to, walking, standing, running, sprinting, jumping, shuffling, diving, or other activities.

In an example embodiment, insole base layer 34 can be designed for a combination of any type of movement. For example, and without limitation, insole base layer 34 of the insole may be designed for (1) standing and walking, or (2) standing, running, and sprinting, or (3) any other activity or combination of activities.

FIG. 7 shows example, representative acts or steps which may be included in a method of fabricating or making an example embodiment of footwear 20 of the technology disclosed herein.

Act 7-1 comprises performing or obtaining a scan, preferably a 3D scan, of the wearer's/user's feet using any type of 3D scanner or apparatus/method for/of converting a 3D object into data that can be viewed on a computing device. Act 7-2 comprises performing or obtaining a pressure map of the user's feet for multiple types of motion, for example, and without limitation, running, jumping, standing, or walking, and collect data. This data can be used to influence the configuration of the lattice structure. Act 7-3 comprises performing a gait analysis or otherwise obtaining gait analysis data that can be used to influence the configuration of the lattice structure. The 3D scanning of act 7-1 and the pressure mapping of act 7-2 may be done at the same time, if desired.

Act 7-4 comprises using the 3D foot scan data obtained as act 7-1, the pressure mapping data obtained as act 7-2, and the gait analysis data obtained as act 7-3 to generate the desired topology, lattice structure, and functional zones 40 of the insole 28. Act 7-5 comprises manufacturing or making the insole base layer 34 by additive manufacturing or other manufacturing means. Act 7-6 comprises manufacturing or making insole top layer 36 by additive manufacturing or other manufacturing means, or cutting material of top layer to the desired shape from a pre-existing material. Act 7-7 comprises affixing insole top layer 36 to insole base layer 34. Act 7-8 comprises providing any desired final touches to insole 28, if necessary, for example, if part of the top layer needs to be trimmed it can be done at this time.

FIG. 8 shows an example embodiment and mode of apparatus 50 which may be employed for fabricating or making footwear according to example modes of the technology disclosed herein. The apparatus of FIG. 8 comprises processor circuitry, generally depicted as processor 52; input interface 54; database or other memory 56; output interface 58; insole base layer fabricator 60; an optional insole top layer fabricator 62; an optional affixation apparatus 64 for affixing insole top layer 36 to insole base layer 34; and, an optional finalization or finishing apparatus 66.

FIG. 8 also shows acts performed by processor circuitry 52 of apparatus 50 when executing instructions of a computer program product stored on non-transitory tangible media such as in memory. The computer program product executed by processor 50 may herein be referred to as footwear fabrication program 70.

In its execution by processor 52, footwear fabrication program 70 may receive various inputs through input interface 54. Among the inputs to input interface 54 shown in FIG. 8 are wearer foot scan data 80; wearer gait data 82; wearer/user or intended use data, e.g., use and user data 84; data describing or pertaining to insole top layer 36, e.g., “top data” 86; wearer foot pressure mapping data 88; and, corrective adjustment data 89. As understood from above, e.g., with reference to act 7-1, the wearer foot scan data 80, preferably a 3D scan, may be procured using any type of 3D scanner or apparatus/method for/of converting a 3D object into data that can be viewed on a computing device. The wearer pressure mapping data 88 may comprise dynamic foot pressure measurements. For example, the dynamic pressures on a user's foot may be measured during dynamic foot activities, such as: running, walking, jumping, landing, pivoting, rolling, rocking, and the like. The wearer pressure mapping data 88 and wearer gait data 82 may be obtained through conventional equipment, either in conjunction with one another and the wearer foot scan data 80 or individually.

The top data 86 may be input as a file which may be created in response to automated or operator response to a menu which requests input or parameters describing the desired or required insole top layer 36.

The use/user data 84 may comprise data regarding a particular user's physical characteristics or attributes—so called “static” user data. For example, a user's foot size and static foot pressure (e.g., when standing) may be measured. The use/user data 84 may also comprise data related to intended use of the footwear 20. Virtually any functional biomechanical measurements may be used during the design of the insole base layer 34.

In its execution by processor 52, footwear fabrication program 70 may also receive various inputs from database 56. Among the database input may be a materials file, e.g., materials 90, which includes information concerning potential materials which may be selected by footwear fabrication program 70 in the configuration of the insole base layer 34, including properties and parameters associated with the respective materials. Another database input may be a file of functional zone configurations 92 which describes various potential patterns of zone combinations, arrangement/location (e.g., central toe zone, a peripheral toe zone, a central arch zone, a peripheral arch zone, a pronation heel zone, a supination heel zone, by way of non-limiting and non-exhaustive examples), and sizes which may be suitable for the insole base layer 34 based on the input applied through input interface 54. A further database input to footwear fabrication program 70 may be a file of formative structures 94 which describes potential zone structures such as, without limitations, beams, lattices, regular 3D grids, regular or irregular open or closed cell structures, foam or sponge-like formations, trusses, springs, shocks, triclinic structures, monoclinic structures, orthorhombic structures, hexagonal structures, triagonal structures, tetragonal structures, cubic structures, stochastic structures, or auxetic lattice structures.

Yet another database input to footwear fabrication program 70 may be a file of statistical population data 96 which may comprise non-user-specific data, such as a for example, the average shape of a foot of a certain size may be statistically determined, or otherwise available from existing statistical datasets. Further, the statistical averages for these and other physical foot characteristics may have associated statistical parameters, such as distributions, standard deviations, variances, and others as are known in the art. In this way, knowing a single foot characteristic associated with a user/wearer, such as a shoe size, may enable the use of many associated statistical foot characteristics, e.g., shape, size, etc.

When executed by processor 52, the footwear fabrication program 70 of the example embodiment and mode of FIG. 8 may execute acts such as those shown in FIG. 8. Act 8-1 comprises receiving data input to footwear fabrication program 70 through input interface 54, such as but not necessarily limited to the wearer foot three dimensional scan data 80, wearer gait data 82, wearer intended use data 84, top data 86, and wearer foot pressure mapping data 88 mentioned above. Act 8-2 comprises accessing the database 56 in order to procure files or information in order to perform at least acts 8-3 through 8-6. In fact, during one or more of the acts 8-3 through 8-6 the database 56 may be accessed or consulted in order to obtain files or information germane to each act.

Act 8-3 of footwear fabrication program 70 comprises generating an overall topology or footprint shape for the insole base layer 34. Act 8-4 comprises determining a number and locations, and sizes, of the plural zones zone 40 which are to comprise or form insole base layer 34.

As an optional aspect, act 8-4 may also comprise determining an interface between adjacent zones, e.g., a zone interface between at least two of the plural functional zones. In an example embodiment and mode, the zone interface may be configured in dependence upon the material structure of adjacent plural functional zones.

Act 8-5 comprises determining a structure for each zone 40. As described above, the structure selected for a zone 40 may be, for example, beams, lattices, regular 3D grids, regular or irregular open or closed cell structures, foam or sponge-like formations, trusses, springs, shocks, triclinic structures, monoclinic structures, orthorhombic structures, hexagonal structures, triagonal structures, tetragonal structures, cubic structures, stochastic structures, or auxetic lattice structures. Act 8-6 comprises determining a material(s) for each zone 40.

The selection and/or determinations of act 8-4 through act 8-6 may be performed through a look up table system wherein combinations of input data received through input interface 54 may be utilized in order to locate an appropriate corresponding insole base layer configuration. For example, an ordered array of input values may match or correspond to a particular insole base layer design which has a pre-stored association of zone configuration (number of zones, locations of zones, and sizes of zones), zone structures, and zone materials. As an alternative to a lookup table approach, the footwear fabrication program 70 may include logic or intelligence for assessing the inputs received through input interface 54 and using certain weights for the input and/or programmed criteria, determine the appropriate parameters of zones, zone materials, and zone structures. It should be understood that the acts 8-4 and 8-6 need not be executed strictly in the order shown, and moreover that one or more of acts 8-4 through 8-6 may be executed essentially concurrently or iteratively in order to optimize the determinations thereof.

Upon completion of execution of act 8-4 through 8-8, footwear fabrication program 70 may generate data for driving base layer fabricator 60 as shown by act 8-8. But as an optional act 8-7 the fabricator driving data footwear fabrication program 70 may determine if any corrective adjustments should be performed for fabrication of insole base layer 34. Act 8-7 and other optional acts or optional equipment are shown by broken lines in FIG. 8. The corrective adjustment act 8-7 may also be executed in an order different than as shown in FIG. 8, or in conjunction or simultaneously with one or more acts 8-4 through 8-6 inclusive. The information 89 pertaining to one or more corrective adjustment(s) may be input to input interface 54 or otherwise. A discussion of various corrective adjustments ensues subsequently. Consideration and processing of corrective adjustment data may cause footwear fabrication program 70 to generated corrective data for driving the insole base layer fabricator 60.

Act 8-8 shows footwear fabrication program 70 generating, as a result and based on execution of previous acts, data for driving the insole base layer fabricator 60. The insole base layer driving data may be output as a file or series of signals to output interface 58, which in turn communicates with the insole base layer fabricator 60. As mentioned above, the insole base layer fabricator 60 may be an additive manufacturing apparatus, such as a three dimensional printer.

If the insole 28 is designed to include insole top layer 36 in addition to insole base layer 34, as act 8-8 the footwear fabrication program 70 generates data for driving insole top layer fabricator 62. The insole top layer fabricator 62 may also be an additive manufacturing apparatus, or other type of apparatus including an apparatus which selects pre-fabricated structure from an existing stock of insole top layers. FIG. 8 further reflect operations in which the insole base layer 34 made by insole base layer fabricator 60 and the insole top layer 36 made or selected by insole top layer fabricator 62 is conveyed or directed to affixation apparatus 64. As described above, the affixation apparatus 64 may secure the insole top layer 36 to the underlying insole base layer 34 by any suitable technique, such as, for example, adhesive, glue, hook-and-loop fasteners.

Since the technology disclosed herein is not limited to insoles that comprise both insole base layer 34 and insole top layer 36, but may also be directed to insoles that have only insole base layer 34, act 8-8 is shown as optional in FIG. 8, as is insole top layer fabricator 62 and affixation apparatus 64.

A further optional apparatus is finishing equipment 66 which may perform any polishing, tweaking, trimming, or other type of adjustment to the insole 28, whether it be a multi-layer insole 28 with both insole base layer 34 and insole top layer 36, or an insole 28 having only an insole base layer 34.

As mentioned above, the footwear fabrication program 70 may be configured to implement optional act 8-7 for determining corrective adjustments to the insole 28. Several examples and a discussion of aspects of corrective adjustments or corrective features are now described.

In an example embodiment, the lattice structure in insole base layer 34 may be configured to compensate for certain variables, such as difference in leg length or movement of the foot. For example, the lattice structure for a left leg may be made shorter than the lattice structure for a right leg to compensate for different leg length in individuals. The lattice structure may be made thinner or thicker, e.g., shorter or taller, by using fewer or more unit cells, or larger or smaller unit cells, respectively, in the design of the lattice structure.

In an example embodiment, the lattice structure may be configured to correct certain movement of the foot of the user. For example, the lattice structure may be configured to correct pronation and/or supination, such as by designing the structure of the lattice in insole base layer 34 to be tilted towards the medial or lateral side. In an example embodiment, the lattice structure is designed to evenly distribute pressure from the foot across the entire insole.

In an example embodiment, corrective features are meant to correct anatomical or biomechanical problems with a user's foot. For example, a user may have a relatively high arch on one foot and a relatively low arch on the other, which creates support issues with regular footwear. As such, in an example embodiment, insoles described herein may include support underneath the high arch and the low arch in order to better distribute the user's weight in the footwear.

In an example embodiment, corrective features are meant to prevent injury rather than to correct an injury. For example, data can be collected when the user is performing a dynamic exercise (e.g. running) and used to determine the balance of a user's foot during movement. The determined balance may be compared to optimal balance data, which may be derived from other dynamic data or statistical data characterizing users who avoid injuries over long periods of time. Thus, corrective features may be designed into insole base layer 34 of the insole to provide better foot balance during movement in order to prevent injury.

In further example embodiments, corrective features may improve performance rather than correct an existing problem or prevent a potential problem. For example, it is known that characteristics of initial foot contact during running are related to running speed. Because of this, dynamic data may be collected to determine characteristics of a user's initial foot contact during running. Thus, an insole may be designed to change the user's initial foot contact to improve running speed and/or efficiency.

Corrective features may, for example, comprise areas of reduced or increased thickness in the lattice structure of insole base layer 34 of the insole. For example, an insole may have an area near the arch with increased thickness to provide additional support to the arch.

Corrective features may also comprise lattice geometry designed in a way to reduce tibial acceleration when running heel to toe by designing the heel and surrounding areas of insole base layer 34 to compress accordingly.

Corrective features may also comprise lattice geometry that enhances or inhibits bending of an insole in certain directions. The number, thickness, direction, and relative proximity of such corrective features may influence the propensity of the insole to bend in certain directions. Certain unit cells may be used in a particular functional zone in order to enhance the tendency for the insole to bend in a designed direction and to counteract the tendency to bend in an undesirable direction.

Furthermore, different materials can be used within the lattice geometry of the insole base layer 34 to inhibit bending, provide more support, and to achieve a certain compression response for that specific functional zone within insole base layer 34 of the insole, among other things. For example, if the user has plantar fasciitis and requires the insole to be more rigid in certain locations, then plastic and rubber may be used interchangeably while constructing the lattice geometry of insole base layer 34 to increase stiffness in certain areas.

Corrective features may also include the ability to design insoles that apply to each foot's individual support needs. This includes, but is not limited to, the shape, the pressure distribution, the required arch support, and the desired compression response at different locations of the user's foot, among other things.

Corrective features may also include one or more functional zones 40. These functional zones 40, in some example embodiments, may be formed out of or comprise unit cells. Functional zones 40 may influence the characteristics of an insole, such as the mechanical behavior of an insole.

Additionally, characteristics of connection points between functional zones 40 may also influence characteristics of an insole. For example, the thickness of a connection point may affect the mechanical properties of an insole. In some instances, connection points can be, for example, selectively thickened or thinned in order to affect the way an insole reacts to different loads in different directions.

In some instances, the corrective features may be on the surface of an insole. For example, surface features such as textures, patterns, lines, or others as described above may be used to provide, for example, more grip, more feel, or more comfort, to a user of the custom footwear.

In some instances, one or more of the aforementioned corrective features may be arranged in functional zones 40 associated with an insole. Such functional zones 40 may be configured to influence different mechanical properties of an insole in different areas. In some instances, an insole may only have one functional zone 40, and in other instances an insole may include more than one functional zone.

In sum, the selection, arrangement and physical characteristics of different corrective features in an insole may be used to correct or counteract a user's biomechanical issues, prevent injuries, and/or promote increased performance.

The technology disclosed herein thus encompasses improved insole designs and compositions, and provides insoles that may be designed and tailored to each person's individual physiological data. The insoles may be designed with lattice geometry that comprises multiple load-compression profiles within the same monolithic part that can be mechanically tuned in order to individually and ideally support each of the user's feet while still allowing for breathability. Rigidity, stability, improved fit, and cushion may all be a part of the same, 3D printed, monolithic lattice structure.

The insoles described in various example embodiments and modes herein may comprise one or two layers, e.g., insole base layer 34 and (optionally) insole top layer 36. The insole base layer 34 may be comprised of a lattice structure with multiple functional zones 40 within a monolithic part and may be made using additive manufacturing techniques. In an example embodiment and mode, insole base layer 34 comprises an optional piece of material adhered to the top of the base layer and comes into contact with the bottom, and in some cases, a side of a user's foot.

The footwear 20 described herein and encompassed hereby may be beneficial for the treatment of a variety of known conditions related to the foot. For example, pronation in the foot (i.e. inward roll of the foot while standing, walking and running) may lead to swelling and Achilles tendon issues. To treat the pronation, footwear 20 may be designed to correct or improve the static and dynamic pressures on the foot. For example, the footwear 20 may correct support under the medial arch of the foot, and may reduce the ability of the footwear to bend in certain directions. As another example, a bunion may be treated with footwear 20 designed to reduce medial load and provides customized support for the hallux (i.e., the big toe). Other conditions may also be treated using the footwear 20 described herein, such as: plantar fasciitis, arthritis, poor circulation, metatarsalgia, patellofemoral knee pain, shin splints, Achilles tendonitis, repetitive strain injuries and others as are known by persons of skill in the art.

In various example embodiments and modes, a 3D printed insole may be designed to treat each foot separately allowing for optimal support for both feet. For example, it is common for someone to have different arch heights causing traditional “off-the-shelf” insoles to inadequately support both feet. 3D printed insoles may be designed to map the bottom of the user's feet individually and ideally, allowing for optimal support, compression control, and functionality for each individual foot, among other things.

In addition to treating existing, adverse foot conditions, the footwear 20 described herein may also help to prevent injuries and the onset of foot conditions. For example, custom footwear may reduce stress related injuries to the foot, ankle, leg, knee, back, etc. by better distributing the weight during the impact of footfalls, or by altering the way a foot falls and rotates during dynamic movements. Similarly, the footwear 20 described herein may prevent movement in certain directions (such as rolling ankle movement) while promoting movement in other directions (such as rolling of the forefoot during transitional movements).

Moreover, the footwear 20 described herein may improve biomechanical performance (e.g., for athletes). For example, the footwear 20 may alter the angle of impact of a foot during dynamic activities such as running, which in-turn may increase the overall speed of the runner.

It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention without departing from the spirit or the scope of the invention as broadly described. The above described embodiments are, therefore, to be considered in all respects as illustrative and not restrictive

Although the description above contains many specificities, these should not be construed as limiting the scope of the technology disclosed herein but as merely providing illustrations of some of the presently preferred embodiments of the technology disclosed herein. Thus the scope of the technology disclosed herein should not be determined by the appended claims and their legal equivalents. Therefore, it will be appreciated that the scope of the technology disclosed herein fully encompasses other embodiments which may become obvious to those skilled in the art, and that the scope of the technology disclosed herein is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” The above-described embodiments could be combined with one another. All structural, chemical, and functional equivalents to the elements of the above-described preferred embodiment that are known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the present claims. Moreover, it is not necessary for a device or method to address each and every problem sought to be solved by the technology disclosed herein, for it to be encompassed by the present claims. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. 

What is claimed is:
 1. An insole for footwear, the insole comprising: at least one layer of insole material, the at least one layer of insole material being configured to comprise plural functional zones, each functional zone comprising a material structure comprised of unit cells, the material structure of at least one functional zone differing from the material structure of at least one other functional zone.
 2. The insole of claim 1, wherein each functional zone is configured individually.
 3. The insole of claim 1, wherein the material structure varies in unit cell shape.
 4. The insole of claim 3, wherein the material structure of at least one functional zone is configured to comprise a beam and lattice construct.
 5. The insole of claim 4, wherein the material structure varies in lattice beam thickness.
 6. The insole of claim 3, wherein the unit cell structure is selected from the group consisting of mass and connector structures and TPMS structures.
 7. The insole of claim 1, wherein the plural functional zones are based on a user's physiological data.
 8. The insole of claim 1, wherein the properties of each functional zone are predetermined with respect to at least compression response.
 9. The insole of claim 1, wherein the at least one layer of insole material is configured to comprise a zone interface between at least two of the plural functional zones, and wherein the zone interface is configured to functionally connect with the material structure of adjacent plural functional zones.
 10. The insole of claim 1, wherein the material structure for the functional zone is configured in dependence upon a characteristic of a wearer of the footwear.
 11. The insole of claim 10, wherein the material structure for the functional zone is configured in dependence upon a desired compression response for the wearer in the functional zone.
 12. The insole of claim 11, wherein the desired compression response for the wearer is predetermined based on the desire of a user of the insole.
 13. The insole of claim 1, wherein at least part of the insole is manufactured using additive manufacturing.
 14. The insole of claim 1, wherein at least two of the plural functional zones are monolithically formed with one another.
 15. Footwear comprising: an exterior sole configured to interface with a contact surface; an upper attached to the exterior sole and configured to at least partially define a cavity for foot insertion; an insole according to claim 1, the insole insertable into or formed within the cavity.
 16. A method of making an insole for footwear, the method comprising: receiving a characteristic of usage of the footwear; and fabricating an insole of the footwear by individually configuring material structure of plural functional zones of at least one layer of insole material in accordance with the characteristic of usage.
 17. The method of claim 16, wherein the characteristic of usage comprises a desired compression response for a wearer of the footwear.
 18. The method of claim 16, further comprising fabricating at least a portion of the insole of the footwear by additive manufacturing techniques.
 19. Apparatus for manufacturing footwear, the apparatus comprising: memory circuitry comprising a stored association of insole material structures with plural footwear usage parameters; an input interface configured to receive usage information concerning an intended usage of the footwear; and processor circuitry configured: to use the stored association and the usage information to generate an insole configuration for an insole for the footwear, the insole configuration comprising plural functional zones of at least one layer of insole material, each functional zone comprising a material structure which is configured individually for the functional zone; and to generate insole configuration output to a footwear fabricator configured to make the insole according to the insole configuration.
 20. The apparatus of claim 19, wherein the processor circuitry is configured to control the footwear fabricator. 